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Senior Product Engineer

Plexus · Appleton, WI · Full time

Posted Aug 25, 2026 · We last checked this listing on Oct 6, 2026

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Likely interview questions for this role

Written from this job description, not a generic list. Each one notes what the interviewer is really checking.

About your past

Tell me about a design-for-manufacturability issue you found and how you got the customer to change their design.

What they are checking: Whether they can influence a customer's engineers with evidence, since the customer owns the design.

Describe how you've supported a new product introduction from prototype to volume production.

What they are checking: Whether they've seen the full ramp and know what usually goes wrong between first builds and steady production.

Tell me about a time you mentored a junior engineer or technician on troubleshooting.

What they are checking: Whether a senior engineer builds others' skills, which helps the whole site keep up with customer demands.

What would you do

Yield on a printed circuit board assembly drops from 98 percent to 90 percent over two weeks. How do you investigate?

What they are checking: Whether they work methodically through data, process, materials and changes instead of jumping to one favorite cause.

A customer is upset about a field failure and wants answers today. You don't have them yet. What do you say?

What they are checking: Whether they stay honest about what is known while giving the customer a clear plan and timeline.

About the work

At a contract manufacturer like Plexus, what does a product engineer own between the customer's design and the build on the floor?

What they are checking: Whether they understand the bridge role of turning a customer's design into something the factory can build reliably.

Walk me through how you'd handle an engineering change order from a customer that affects parts already in inventory and work in process.

What they are checking: Whether they think through cutover, inventory, costs and documentation, where sloppy ECO handling causes mixed builds.

How do you decide whether a recurring defect is a design problem for the customer or a process problem for the factory?

What they are checking: Whether they can separate root causes fairly, which matters when the answer decides who pays to fix it.

How do you use test data, such as in-circuit or functional test results, to drive improvements?

What they are checking: Whether they treat test data as a source of insight, not just a pass or fail gate.

In medical or aerospace programs, what changes about how you make process or design changes?

What they are checking: Whether they respect validation, documentation and customer approval in regulated builds, where unapproved changes are serious.

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The full job description

As published by Plexus.

About us: At Plexus, our vision is to help create the products that build a better world. Driven by a passion for excellence, we partner with leading Aerospace/Defense, Healthcare/Life Sciences and Industrial companies to design, manufacture and service some of the world’s most transformative products, including advanced surgical systems, diagnostic instruments, healthcare imaging equipment, mission critical aerospace systems, and electric vehicle (EV) charging solutions. Visit Plexus.com to learn more about our unwavering commitment to our vision. When we invest in our people, we invest in building a better world. With a vision rooted in the wellbeing and inclusive engagement of our team members, our customers, their end users and our communities, people are the heart of what we do and who we are. It is our values that unite us and guide us in everything that we do, including how we operate, behave and interact to foster a workplace where every team member feels valued and empowered to contribute their best. Our values include: Growing our People, Building Belonging, Innovating Responsibly, Delivering Excellence and Creating Customer Success. As a team member, you will engage in impactful work through global collaboration and the use of emerging technologies, join an inclusive culture where every team member is valued and working toward a greater purpose, and be empowered to reach your full potential through various development programs designed to accelerate your growth. Employer: Plexus Corp. Job Location: Appleton, WI Title: Senior Product Engineer Duties: Engage in customer technical communications, product initiation, product-level continuous improvement and sustainment. Key job accountabilities include continuous improvement, technical customer support, manufacturing readiness, sustaining production, and operations support. Conduct continuous improvement efforts at the product level to reduce defects, improve yields, and improve productivity in order to deliver customer excellence and achieve Plexus’ enduring goals. Serve as the technical expert on Plexus site manufacturing as it relates to the customer’s product. Capture customer requirements and translate requirements into a manufacturing solution. Support on-going production activities to ensure Plexus continues to meet customer needs and achieve internal goals. Provide technical support and expertise to manufacturing personnel. Position requires no more than 10% domestic and international travel to other Plexus facilities or to customer sites. Position may require supervision of up to two Manufacturing Technicians. Requirements: Bachelor’s degree in Mechatronic, Mechanical, Manufacturing Engineering, or a related field, and 3 years of experience in a Product Engineering, Process Engineering or a related role. Experience must include: • 3 years of product engineering experience within an assembly or fabrication manufacturing environment including developing, deploying, and sustaining processes. • 3 years of experience in Failure Mode Effects Analysis within the Advance Product Quality Planning (APQP) framework. • 3 years of experience using 8D (Eight Disciplines) quality problem methodology. • 3 years of experience using Design for Manufacturability (DFM) and Design for Assembly (DFA) • 3 years of experience working on projects using DMAIC (Define, Measure, Analyze, Improve, and Control) methodology • 3 years of experience establishing workflow processes, fixtures, and tooling to achieve robust and efficient manufacturing processes Salary: $97,820 per year Applicants must be U.S. workers (includes U.S. citizens, permanent residents, foreign nationals granted temporary residence under one of the 1986 legalization programs, refugees, and asylees). We are pleased to provide reasonable accommodations to individuals with disabilities or special requirements. If you need an application accommodation, please contact us by email at GHQ.TA@plexus.com. Please include your contact information and clearly describe how we can help you. This email is for accommodation requests only and cannot be used to inquire about the status of applications. We are an Equal Opportunity Employer (EOE) and do not discriminate based on race, religion, color, national origin, gender, sexual orientation, age, marital status, veteran status, or disability status.

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